Stäubli 'is your production partner for efficiency'

Stäubli has been providing the plastics industry with innovative quick release connectors for over 60 years, helping moulders and transformers improve productivity, safety and efficiency. Stäubli Connectors Group Divisional Manager Andre Lucchetti gets the Q&A treatment on how Stäubli identifies the changing needs of the sector and responds with new products and solutions.

Staubli

When did Stäubli’s business with the plastic sector start?

This year we celebrate the 60th anniversary of our Connector Division and the plastics market has been at the core of our business right from the beginning. During this period we have been central to and often the pioneer of technologies such as the 'straight-through' restriction-free couplings, valved connectors for increased safety, through to multi connection systems either for single or multi media.

Furthermore, the plastics industry is an ideal environment for Quick Release Couplings, the demand for faster and safer mould changes is relentless.

This type of environment is ideal for Stäubli; we are innovators who constantly look forward. This ethos and our closeness to our customer base has meant that we have developed our product portfolio from purely quick release mono and multi-couplings to now include mould clamping and loading technologies.

We are now, in conjunction with our Robots Division, a true solution provider. Stӓubli’s 4-axis and 6-axis robots provide excellent demoulding and second operation solutions such as deburring, assembly and packaging. They are fast, extremely reliable and small enough to be accommodated easily into most production cells. The latest co-operative robot technology ensures safe interaction in the production cell between man and machine. Control software, specifically written for use in plastics moulding, is easy to use and compatible with other systems.

How did the market respond to these developments?

Injection moulders could readily see the benefit of being able to disconnect moulds quickly and safely from their thermal regulation and fluid circuits. The use of quick release connectors in place of fixed connections often brings the single most significant reduction in mould change times.

In fact we quickly saw the additional advantage of putting all the connections together on one plate, connecting all circuits simultaneously with no danger of crossed or miss-connection. Our response was to introduce a range of modular standard multi-coupling plates. As mould technology developed and more media was required at the tool, the option of designing bespoke plates to meet precisely the requirements of these applications became important.

Moreover, Stäubli extended our expertise in electrical connectors with the acquisition of Multi-Contact in 2002. So we are able to provide a full offering of fluid, electrical power and signal connectors in any combination required by the application.

What’s your view on how manufacturers should approach the task of speeding up mould changes?

It’s important to start from the basics; significant benefits can be gained at minimal expense, the use of quick release couplings on the mould can often reduce tool change over from hours to minutes.

Where applicable, the next step should be to consider the benefits of putting all connectors together on a bespoke plate, even electrical and signal circuits can be included. Consideration of mould clamping, mould transfer and loading should then follow. These are all tasks that need to be addressed if you wish to optimise production efficiency by reducing machine downtime.

Do you favour any specific technique of quick mould clamping?

Stäubli are unique in manufacturing mechanical, hydraulic and magnetic mould clamping systems. This is our deliberate policy so that we can suggest the most appropriate technique for any specific application.

Mechanical systems are very often easy to install since they require no hydraulic or electrical connections. They can be readily fitted to most injection moulding machines below a maximum closing force of 300 tonnes. However the selection of the mechanical system cannot be made on the size of the machine alone; the quantity of moulds deployed in the machine is also a very important economic factor. As a general rule the higher the quantity of moulds the more consideration should be given to magnetic clamping. In the case of larger machines either hydraulic or magnetic systems will be necessary, the choice depending on the quantity and variation of moulds. Magnetic systems normally require no modifications to the mould which can represent a significant cost saving, while on hydraulic systems a back plate is almost always needed which, dependant on the quantity of moulds, can substantially increase the investment.

Not to be forgotten when choosing between magnetic and hydraulic technologies is the increased safety and data storage capabilities of the magnetic systems.

We have devised software that provides a step-by-step guide to help evaluate the options and select the most suitable system.

The choice of the most suitable system for any given application is far from straightforward and the user must give really close consideration to both their current and future needs.

Is the use of quick mould clamping systems increasing?

End users are increasingly insisting that injection moulding machine manufacturers incorporate clamping systems in their machines. This demonstrates that across the sector knowledge of the benefits of these types of systems is increasing. This in turn creates demand to retrofit systems to existing machines. Although it must be stressed that clamping is only a part of the quick mould change process.

In the vast majority of cases the most significant savings can come from reducing the time taken to disconnect and connect the thermal regulation lines. It is absolutely true that in many cases the maximum gain comes from the lowest investment.

What else should be considered to achieve quicker mould changes?

Mould transfer and loading is often a neglected area, many regard it as a luxury. This is not always the case. Simple mould transfer and loading carts can be very economical, serving a range of machines and giving a payback on investment of just a few months. Handling moulds securely and preventing costly damage while improving operator safety are added benefits.

For heavier moulds, systems right up to fully automated rail mounted carts are the solution. Individually designed to suit specific application and user needs.

Pre-heating stations can be included to ensure that the mould is at operating temperature ready for immediate use, again helping to minimise downtime.

What is the role of customer service in supporting your activities?

We like to work closely with all our customers which is why we have facilities around the world. The selection of the correct technology and the correct processes are imperative if you are to maximise your investment. At Stäubli this is our business, every day we are assisting a vast number of companies to maximise the efficiency of their moulding operations. Stäubli is about far more than our products it is about our knowhow. A Stäubli engineer is close by and on hand to explain the technology, advise on selecting the appropriate solution and able to work alongside the production team to ensure efficient installation and operation.

This service is available to all sizes of companies, large, medium and small. Frequently the most successful solutions are low cost, but capable of yielding a significant production advantage; typically using quick release connections is the most important and rewarding change that manufacturers of any size can make.

At Stäubli our aim is to ensure all customers choose the most suitable system, one capable of operating safely and securely over many years, meeting the financial and productivity goals established at the outset. That is the essence of our partnership for efficiency.

What shall we see from Stäubli at the K Show?

Staubli Robot Cell

We continue to innovate by extending our range of products and services, anticipating the future demands of the plastics market. Recent new products are robust quick release connectors capable of working safely at the higher temperatures being used in injection moulding and a secure reliable electrical multi connectors capable of handling all the electrical circuits on a moulding tool. Both of these will be displayed on our stand.

The demands of the Smart Factory and the opportunities raised by Industry 4.0 are also being addressed; on the stand there will be an interactive and operational injection moulding cell, complete with mould connections, mould clamping, handling and loading as well as robotics. The robots will demonstrate their ability to work safely alongside operators within the production cell. Visit our stand (Hall 11 Booth H21) to view the latest developments in QMC technology and discuss your specific requirements with our engineers.